battery ASTON MARTIN DB7 1997 Workshop Manual

Introduction
/^r"^^^^^3^
'"'P ?
Safety Precautions L —^ ^^—^
Safety Precautions "
All service workshops are a source of potential danger and repair work should only be performed by technically
trained staff following the procedures in this manual. A safety conscious approach to the performance of all service
procedures must be observed at all times. Statutory requirements governing all aspects of health and safety at work
including directives for the proper use of materials and equipment must be implemented.
The following contains a list of particular safety precautions which should be observed; it is not intended to be
exhaustive.
Air Conditioning System
Do not disconnect any air conditioning refrigerant system pipes unless trained and instructed to do
so.
The refrigerant
used can cause blindness if allowed to contact your eyes.
Chemical Handling and Storage
Chemicalsusedintheservicingofmotorvehiclesincludeacids,adhesives, antifreeze, brake fluids, coolants, grease,

oil,
paint, resin and solvents. Exposure to certain chemicals through direct contact or inhalation can be
fatal.

Potential hazards may also be present through the incorrect use, storage and handling of chemicals causing a fire
risk. The following precautions should be observed.

1.
Strictly adhere to handling and safety information found on containers and labels.

2.
Do not store chemicals in unlabelled or incorrectly labelled containers.
3. Containers used for storing chemicals should not be left
open;
there is a risk of
spilling,
or evaporation of fumes
which may be inflammable or toxic.

4.
Do not mix chemicals unless instructed to do so following manufacturers guidelines.
5. Do not inhale chemical materials to determine identity, they may be toxic.
6. Do not use petrol, kerosene, diesel
fuel,
gas oil, thinners or solvents for washing
skin.

7. Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages.
8. Chemicals based on solvents such as paint should not be sprayed in a confined space; work areas used for
such operations should be well ventilated and fume extraction equipment should be utilised.
9. Ensure that adequate ventilation is provided when volatile de-greasing agents are being used.
WARNING: Fume extraction equipment must be in operation when
solvents
are
used
e.g.
trichloroethane, white
spirit, SBP3, methylene chloride, perchlorethylene.
WARNING: Do not smoke in the vicinity of volatile de-greasing agents.

10.
Avoid splashing the
skin,
eyes and clothing.

11.
Clean chemicals from the skin and clothing as soon as possible after soiling.

12.
Wear protective clothing such as goggles, non porous gloves and apron when hand
I
ing battery acid and other
corrosive and toxic substances.
iv April 1997

//—-^
^^^^5~^
' -^ ^ Introduction
Safety Precautions
Safety Precautions (continued)
Electrical Equipment

1.
Ensure that electrical equipment is in safe working order before use.

2.
Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly

earthed.

3. Ensure that electrical equipment is protected by a fuse of the correct current rating.

4.
Disconnect the battery before commencing repair operations to the electrical system, fuel system and engine
or when working beneath the vehicle.
Exhaust Fumes
Engines should not be run in confined spaces, exhaust fumes contain harmful and toxic substances including carbon
monoxide which can prove fatal if inhaled. Engines must only be run where there is fume extraction equipment in
operation or where there is adequate ventilation.
Fire Precautions

1.
Ensure that a suitable form of fire extinguisher is conveniently located near the work area.

2.
Keep oils, solvents and combustible materials away from naked flames and other sources of ignition.
3. Ensure that NO SMOKING signs are posted around areas where combustible materials and vapour may be
present and ensure that the warnings are strictly observed.

4.
Ensure that dry sand is available to soak up any spillage of fuel or other flammable solutions.
5. Fume extraction equipment must be available and in full working order to remove combustible and toxic
vapours.
6. All personnel should be aware of the fire drill procedures and precautions.
Jacking and Lifting

1.
The recommended procedures for lifting, jacking and towing are included latefin this seetion-and must be
strictly observed to ensure personal safety.

2.
Always use a vehicle hoist, ramp or pit for working beneath the car in preferencetd^&^cking
3. Never rely on a jack to support a car independently, use axle stands or blocks carefully pJaQed at the jacking
points to provide rigid support.

4.
When working beneath a vehicle, chock the wheels as well as applying the handbrake.
5. Ensure that the vehicle is standing on firm level ground before jacking or lifting.
5. Check any lifting equipment used has adequate capacity for the load being lifted and is ih"fdll working order.
Tools and Equipment

1.
Do not leave tools, equipment, spilt oil, etc. around or on the work area.

2.
Ensure that tools and equipment used are in good condition; do not use damaged or defective tools or
equipment.
3. Do not apply heat in an attempt to free stiff nuts or fittings; as well as causing damage to protective coatings,
there is a risk of damage to electronic equipment and brake lines from stray heat.

4.
Use the recommended service tool where instructed to do so.
April 1997 v

[EM^^^

Electrics
Wiper Motor / Alternator - Removal Procedures
6.2.01 Windscreen Wiper Motor 6.3.01 Alternator
Procedure

1.
Disconnect the battery.

2.
Disconnect the wiper motor multi-plug.
3. Remove the nut and lockplate (Fig 1-1) from the
motor gearbox shaft and release the drive bracket
from the shaft.
Figure 1. Windscreen Wiper Motor

4.
Remove three nuts (Fig
1
-2) and remove the motor
from its mounting bracket.
Procedure

1.
Disconnect the battery earth
lead.

2.
Using a 3/8" ratchet handle, release the drive belt

tension.
Slip the belt from the water pump drive
pulley and from the alternator drive pulley.
3. Release the ignition leads from the support on the
alternator top mounting.

4.
Remove the alternator output lead cover, remove
the nut and washers and disconnect the alternator
output
lead.

5. Disconnect the electrical plug on the rear of the
alternator.
6. Remove the alternator lower mounting bolt.
Figure 1. Alternator Mountings
7. Loosen the alternator upper mounting bolt, support
the alternator, remove the upper bolt and the
alternator.
Replacement is the reverse of the removal procedure. The
drive belt is tensioned automatically by the spring loaded
idler on refitting the main drive belt.
May 1996 6-5

Electrics
Starter Motor / Steering Wheel - Removal Procedures ^n:M3^^2?
6.3.02 Starter Motor
Procedure

1.
Disconnect the battery.

2.
Remove the inlet air trunkins
Figure 1. Starter Motor Mountings
3. Disconnect the starter solenoid connector and the
starter motor power lead at the solenoid.

4.
Remove the top starter motor securing bolt.
Note:
The
top bolt is from tlie
engine
side on auto
cars

and from ttie gearbox side on manual cars.
5. Raise the car on a hoist and whilst supporting the
motor, remove the lower starter motor securing
bolt.
6. Lift the motor from the bell housing and remove it
from the vehicle by positioning it vertically and
lowering it down in front of the oil filter.
6.5.01 Steering
Wheel and Horn
Switches
Procedure

1.
Remove the steering wheel centre pad.
Figure 1. Steering Wheel and Horn
2. Mark the position of the steering wheel relative to
the steering column to ensure correct replacement.
3. Removethesteeringwheelsecuringnutand remove
the steering wheel.
6.5.02 Column Switches
Procedure

1.
Remove the steering wheel.

2.
Remove three screws and the column switch cover.

1^

Figure 1. Column Mounted Switches
3. Cut the tywraps securing the switch loom to the
steering column. Disconnect the loom plugs.

4.
Release 4 screws and
1
ift the switch assembly off the
steering column.
6-6 May 1996

Em3^^^

Electrics
Ignition Switch / Instrument Panel - Removal Procedures
6.5.03 Ignition Switch 6.5.04 Instrument Panel
Procedure

1.
Disconnect the battery.

2.
Remove three screws and the steering column
lower cover.
Procedure

1.
Disconnect the battery.

2.
Remove the four screws from the instrument pane!
surround and remove the surround.
Figure 7. Ignition Switch
3.

4.

Loosen thegrub screw securing the switch and ease
the switch from its location.
Disconnect the switch multi-plug and remove the

switch.

Figure 1. Instrument Panel Removal
3. Remove two screws from the top edge of the
instrument panel and withdraw the panel.

4.
Detach the three electrical connectors and remove
the instrument panel.
5. Panel warning lamps are 1.2W bayonet fit. The
larger panel illumination lamps are also 1.2W
bayonet fit.
May 1996 6-7

Electrics
Electric Windows - Fault Analysis / Window Motor Removal
[n:m3^^

Electric Windows
Description
Power to the window wind circuits is available
when the ignition switch is on and is supplied
through a thermal cut-out to the left and right
window switches. The switches are double pole
plus earth so that the current through a window
motor may be switched in either direction to raise
or lower the window.
DB7 uses frameless door windows which seal
against rubber strips around the body shell door

opening.
To avoid damaging these seals during
door opening, the door glass must be lowered
before the door can be opened. This function is
controlled by the window control units. The units
are mounted on the inside of each door frame and
will sense if a door handle is pulled to open the
door. Before releasing the door lock, the control
unit will drive the window wind motor briefly to
lower the door window glass down until it clears
the window seals. Similarly, after closing a door,
the window motor will be run to raise the door glass
to seat the glass against the body seals.
Fault Analysis Procedure
a) If a window fails to operate, check for fuse failure
and the connectors for poor or open contacts.
b) Check the thermal cut-out by shorting across it and
operating either window. If the windows operate
with the short
ci rcu
it but not without, the cut-out is
faulty.
c) With the ignition on, battery voltage should be
available between the inputterminalsof the switches
and chassis. Operate each switch and ensure that
battery voltage is available between the switch
output terminals and chassis.
d) Measure voltagefrom each switch inputterminalto
the switch earth return terminal. If no voltage is

measured,
the earth return line is open circuit.
e) Measure continuity through the wiring from the
switches to each motor. If continuity is correct,
remove the motor for bench testing.
6.7.04 Door Window Motor
Procedure

1.
Remove the door trim panel and the glass inner
sealing
trim.

Figure!. Window Securing Screws
2. Position the window to gain access to the slider
bracket and glass securing screws.
3. Disconnect the battery earth
lead.

4.
Remove two screws securing the glass to each of
the two slider brackets. Loosen the two screws
securing the glass to the elevator
rail.

6. Slide the elevator rail forwards until the glass
securing screws are opposite the wide opening of
the rail keyhole slots and remove the glass from the
top of the door.
7. Disconnect the window motor multiplug.
6-14 May 1996

Electrics
Transmission Control Module "3^^
6.7.06 Transmission Control Module
Renew (TCM)
Data
Torque Figures
Nut TCM to mounting bracket 2-3 Nm
Procedure
Disconnect the battery.
1.

2.

3.
Remove the rear seat squab. Remove the rear
quarter trim and the rear quarter lower trim pad.
Remove the TCM to mounting bracket securing
nuts (Fig.
1
-2) and remove one bracket.
Figure 1

4.
Remove the TCM and mounting bracket assembly
from the body mounting bracket (Fig. 1-1).
5. Disconnect the TCM multi plug (Fig. 1-4) and
remove the TCM.
6. Fit and align the left mounting bracket (Fig.
1
-5) to
the new TCM, and secure with two nuts. Connect
the harness multi plug (Fig. 1-4) to the TCM. Fit the
TCM and left mounting bracket assembly to the
body mounting bracket (Fig. 1-1), ensure the left
bracket slot is fully seated.
7. Fit the right mounting bracket (Fig.
1
-3) to the TCM
and to the body mounting bracket. Secure with two

nuts.

8. Refit the rear quarter lower trim pad.
9. Refit the rear quarter trim panel.

10.
Refit the rear seat squab.

11.
Reconnect the battery.
6-16 May 1996

[EM^^^

Electrics
Barometric Pressure Sensor

6.7.07
Barometric Pressure Sensor -
Renew
Data
Torque Figures
Sensor mounting nut 2-3 Nm
Procedure

1.
Disconnect the battery.

2.
Remove the left rear quarter trim panel to access the
TCM and barometric pressure sensor.
Figure 1
3. Disconnect the harness multi plug (Fig. 1-3) from
the barometric pressure sensor (Fig.
1
-4 ).

4.
Release the two securing clips (Fig. 1-5) and
remove the sensor).
5. Fitthe new sensor into position, and secure with the
two clips.
6. Connect the multi
plug.

7. Refit the interior
trim.

8. Reconnect the battery.
May 1996 6-17

Nb 61 62

COLOUR
PIN
BR
1
B
2
}

kKk
B6 CI

BONNET SWITCH
80
RC
es
B
S4
RY 97 Sr
98
YP

NO COLOUH 65
UB
66
U
67
B
68
N
69
UW

t>IN
1 ? 3 4
5
i
-
AREA B6 B3-I3 CI B4-i8 B2-I2

HEADLAMP CONTROL MODULE
NO COLOUR
PIN
63
YO 1
64
YP 2
?
Uiti
C6 CI
NO 70 71
?2

COLOUR
PIN YW YB
YP_.

1 2 3

AREA
C6 C6
V.
.,
SPEED CONTROL
W»
VALVE SPEED CONTROL
PUW
84 N 84-18 85 H eiJi

I BATTERY POST
|

SPL
15
SPL
16

I
i 1 I

rUSEBOX

NO
COLOW
73
R
39
RO
74
N
53
NY

75
UW
34
UW
76
UW
9
UW
77
RS
78
RS
79
RG
80
RC
81
UR
33
UR
82
UR
8
UR
83
WK
6
LG
PIN 1 2 J
4 6 6 7 8
9 10 II 12 13 14 15 16
1/
IS 19 20 21
li

AREA
B3-15
CI
B4-I8
CI

B2-I2
Bl
B2-I2
Bl B6 Dl B6 Dl
B2-I0
61
B2-I0
Bl Be Bl
1 II

^0
D

("

c

D
Q
00=^ Q
D
0
Q
Q
0
Q
Q
QOZ
Q
0
G
G

NO COLOUF 90 GR 14 WU 17 GW 77 RS 83 DM 91 W 92 NR 93 R 61 BR 94 RY 95 U 79 RG 65 UB 87 YR 46 NB 86 BK 4 NP 5 YS
PIN 1 ? 3 4 5 6 7 8 9 10 II 12 13 14 15 16 17
,1?,
,
AREA B4-I6 Bl Bl 03 03 B2-II 83-14 83-15 Al 01 83-13 D3 A2 04 CI 04 Bl Bl

SHEET
8
AREA
Al
.S
^

(•

QQl 0
Gl,
0
G

Qcm

G
0
G
0
G
0

NO COLOUR 96
UW
97
CY

98
YP
70
YW
71
YB
51
RO
15
RO

99
UR
63
YO
50
BR
P»i 1
2 3
4 5 6 7
8 9 10
II 12 1?

AREA 82-12
Dl
01 A3 A3 CI 81

82-10
A2 CI

'LH SIDE REPEATER'
fcRUISE
CONTROL!
CLUTCH
SWITCH

NO COLOUR AREA 88
B Dl
99
{R
E±J1
NO COLOUR AREA 86 BK 86 67 YR B6

^27 Wiring Diagram
Model
-
Aston Martin
DB7
Coupe
Harness Title
-
Left Forward
2

Drawing Part No.
-
B37-81297
Revision
- 0
Sheet
2 of 29
-
Up to 97 MY

NO COLOUR
PIN
116
NV I
I?
B ?

AREA A6
Si.

H6
COLOUR
fiN
ABEX"
125
N I
B3-23 12?
BY 2 SS_

NO
COLOUR
PIN
100
B I
101
PY ?

AREA B2-20 BI-19

HO
COLOUR
117
B
119
B
120
B

AREA
A2 A2

_«
NO COLOUR
PIN
ASET
103
B I CI
105
Py ' CI

NO COLOUR
PIN
102
B 1
103
B 1
lOfl
PT 2
105
PY 2

Ali^A B2-20
Bl
BI-19
fl

EARTH POINT
COOLANT
LOW
LEVEL SENSOR

AIR
CON
RELAY
l«
SPl
19
SPL
20

HO COLOUR
PIN
135
NS 65
136
UB 86
137
KB 87
87A
138
RH 3?

AREA
C6 C6
C3-22

..»,
.

NO COLOUR
PIH
133
P 85
140
PB 86
141
P 87
87A
14?
PY 30

AREA C4-24 ce C4-24

.BLI9..

NO COLOUR
PIH
115
N 85
143
BC 86
144
WY 87
S7A 110
WR 30

AREA 02 B4 C6
C2
NO COLOUR
PIK
146
RY 85
120
8 86
147 KB
87
129
UR 87A
130 BG
30

ARCA
A6 B2 C3-22 03 03 STARTER SOLENOID RELAY FAN
RUN ON
RELAY
NO COLOUR AREA 121
WR £5_

HO COLOUR 124
NG
146
RY
126
BY

116
NY

PIN 85 86 8/ 87A
55
AREA
A2 A5 A2
A2

NO COLOUR
PIH
123
NY 85
127
UN 86
148
KB 87
87A
lie
HY 30

AREA
B2 D3
C3-22

.^2...

l/

NO COLOUR
PIN
106
B I
W-S&
2_

AREA 82-21 C6 LOW LEVEL SENSOR

NO COLOUR PIN
ARET
I 110
WR 2 «4
STARTER MOTOR SOLENOID
NO COLOUR III
B
112
e

AREA B2-2I 82-20
SCREEN WASH PUMP
NO COLOUR
PIN
lOe
B 1
109
LCB 2
3 4
AR^A B2-2I C6 NO 113 114 l|^
COLOUR N N H
AlttA A2 B3-23
M
BATTERY
POSTL

NO COLOUR
133
B
134
aw

AREA B2-2I
J
RH
SIDE n REPEATER
NO COLOUR
PIN
131
YR I
132
BK 2

AREA ce C6 J CRUISE CONTROL ^ CLUTCH SWITCH
c

D:

r

ID ID
i D)

IDczt
mm

ffl
m

m m

ID Ul

ii=ir

i m
m ID

Trff'TsrawPir
134
OW
144
WY
135
NS
136
UB
138
RN
140
PB
IJI
YR
132
BK
121
WR
145
BC

109
LCB

149
P
107
BS

1 2 3 4 5 6 7 8 9
10
II 12 13 14 15 16 17 18 19
_.29
AREA
C4 A4 A3 A3 A5 A4 C4 C4 62 B4
01

C4-24
CI

NO COLOUR
PIN
127
UN 1
128
KB 2
129
UR 3
130
Bf. 4

AREA
AS
C3-22
A5
«5

SHEET
14
AREA
B4

SHEET
6
AREA
B3
^27
Wiring Diagram

Model
-
Aston Martin DB7 Coupe

Harness
Title
-
Right Forward

Drawing
Part No.
-
B37-81298

Revision
- 0
Siieet
3 of
29
-
Up
to 97 MY